Cavalier Starting in the 1980s. the Cavalier made a name for itself by offering an affordable 2 and 4 door compact.
Platform: J-body

Fuel tank access hatch....

Thread Tools
 
Search this Thread
 
Old Jan 11, 2026 | 1:22 PM
  #1  
Jiyu's Avatar
Thread Starter
CF Active Member
5 Year Member
 
Joined: Mar 2020
Posts: 118
Likes: 9
Default Fuel tank access hatch....

Getting ready to cut an access hatch in my 02 Cav, any advice?

Thanks
Reply
Old Jun 10, 2026 | 7:53 AM
  #2  
RD_Atlanta's Avatar
CF Beginner
 
Joined: Mar 2026
Posts: 10
Likes: 2
Default

Did you cut the access? If so, are you happy with it? Could you share photos? And please mention any if you did it again, what would you do differently.
Reply
Old Jun 10, 2026 | 11:01 PM
  #3  
Jiyu's Avatar
Thread Starter
CF Active Member
5 Year Member
 
Joined: Mar 2020
Posts: 118
Likes: 9
Default

Yes, I did it using an angle grinder with a cutting wheel on it. Basically, it's right under the hump in the middle. One of the mistakes I made was not making the forward most cross-cut far enough forward, so I had to cut out some more.
The bigger mistake I made was putting a tiny, almost invisible slice in the fuel line! Looked like nothing until I turned on the ignition and a small fountain of fuel shot out. I knew the lines were there and I thought I was being careful enough, but wasn't. My advice would be, when you make the right-side, front-to-back cut, only cut deeply enough to be able to bend the hatch back and forth until in breaks off completely. That will eliminate the chance of hitting the fuel line.
I fixed it by running a new fuel line from the pump to the filter and took the opportunity of replacing the fuel filter that was very old, so, all good.

Also, the edges of the cuts are going to be very sharp, so do what you can to grind or file them smooth. I also but gorilla tape (duct tape) around the edges. I was going to put hinges on the hatch but didn't bother — just put one of the rear floor mats over it and reinstalled the seat.
Bought the car used from Hertz 22 years ago, still runs great, doesn't burn a drop of oil.
Reply
Old Yesterday | 3:05 AM
  #4  
RD_Atlanta's Avatar
CF Beginner
 
Joined: Mar 2026
Posts: 10
Likes: 2
Default

Very helpful, thank you.
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
macbubba
General Tech
4
Sep 18, 2024 1:57 PM
pocojo
Silverado, Sierra & Fullsize Pick-ups
6
Jun 13, 2023 9:07 AM
dberladyn
Express, Savana & G-Series Vans
3
Aug 12, 2015 7:56 PM
donabar
S-10 & Blazer
1
Mar 8, 2008 3:48 AM




All times are GMT -5. The time now is 11:27 AM.